SEARCH · Search NASA

Results for “microstructural analysis”

Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

SourceResearch connectionFrom yearThrough year

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 1,153 records · Page 64

All sources NASA NTRS DOE OSTI

DOE OSTI2025

Cold-Sprayed NMC622 Composite as a Cathode for Lithium-Ion Batteries

The growing demand for high-energy, low-cost lithium-ion batteries (LIBs) to power electric vehicles (EVs) necessitates advances in both materials and manufacturing processes. Conventional cathode fabrication methods, such as slurry casting and drying, are energy-intensive and pose challenges for scalability and environmental compliance. In this study, we propose cold-spray (CS) deposition as a solvent-free approach for fabricating LiNi 0.6 Mn 0.2 Co 0.2 O 2 (NMC622) composite cathodes. Powder blends of NMC622, poly(vinylidene fluoride) (PVDF), and carbon black (CB) are directly deposited onto stainless steel and Inconel substrates under varied gas temperatures, pressures (and thus velocities), and standoff distances. The effects of temperature on the deposit morphology, coating density, and volume are systematically investigated. Computational fluid dynamics simulations reveal that increasing the gas temperature enhances the particle velocity, narrows the spray angle, and reduces the mass concentration radially at the nozzle outlet. CS deposition results in a dense cathode microstructure, accompanied by fracture in polycrystalline NMC622 particles. X-ray diffraction analysis further verifies that there are no phase changes during the deposition process. The electrochemical performance of the cold-sprayed cathodes reveals an initial capacity of approximately 96 mAh g –1 for single-crystal NMC622 and 167 mAh g –1 for polycrystalline NMC622. While these values are modest compared to state-of-the-art slurry-cast cathodes, which typically exhibit 180–200 mAh g –1 under optimized conditions. The results demonstrate a competitive performance given the solvent-free nature of the CS process and compare favorably with tape-cast samples made from identical feedstock. In conclusion, he CS process enables the formation of dense, binder-integrated cathode coatings without the need for solvent processing, offering a promising pathway for scalable, energy-efficient dry electrode manufacturing of next-generation LIBs.

Batteries↗

DOE OSTI2026

Evaluation of the interfacial bonding strength between hafnia and silica layers deposited by electron-beam evaporation

Factors contributing to the mechanical strength of multilayer optical coatings involving alternating layers of electron-beam evaporated hafnia and silica is investigated. It is observed that upon rupture resulting from nanosecond laser damage, fragments consisting of layer pairs are produced. These pairs are formed as a result of a strong asymmetry in adhesion strength between interfaces, leading to preferential delamination at interfaces where silica is deposited on hafnia, and not the reverse, despite the fact that both interface types consist of the same pair of materials. The observed disparity in adhesion strength was further studied using nanomechanical scratch tests, revealing loads at which fracture occurs, and fracture morphology, both of which are highly dependent on deposition order. Based on these measurements, along with the morphological analysis of the nanostructure of the coatings, we conclude that the surface microstructure in each coating layer affects its adhesion strength with the succeeding layer. The findings outlined here are particularly relevant to the production of large aperture, high-performance optics designed for use in next-generation lasers.

adhesion strength↗

DOE OSTI2015

Ag induced electromagnetic interference shielding of Ag-graphite/PVDF flexible nanocomposites thinfilms

We report Ag nanoparticle induced Electromagnetic Interference (EMI) shielding in a flexible composite films of Ag nanoparticles incorporated graphite/poly-vinylidene difluoride (PVDF). PVDF nanocomposite thin-films were synthesized by intercalating Ag in Graphite (GIC) followed by dispersing GIC in PVDF. The X-ray diffraction analysis and the high-resolution transmission electron microscope clearly dictate the microstructure of silver nanoparticles in graphite intercalated composite of PVDF matrix. The conductivity values of nanocomposites are increased upto 2.5 times when compared to neat PVDF having a value of 2.70 S/cm at 1 MHz. The presence of Ag broadly enhanced the dielectric constant and lowers the dielectric loss of PVDF matrix proportional to Ag content. The EMI shielding effectiveness of the composites is 29.1 dB at 12.4 GHz for the sample having 5 wt. % Ag and 10 wt. % graphite in PVDF.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗

DOE OSTI2023

Corrosion Electrochemistry of Chromium in Molten FLiNaK Salt at 600 °C

The manuscript revisits the corrosion behavior of pure Cr in molten FLiNaK salt at 600 °C from the perspective of corrosion electrochemistry. In this work, the potential-dependent, rate-limiting charge-transfer, and salt film-mediated mass-transport controlled regimes of Cr corrosion in FLiNaK at 600 °C are investigated. The kinetic and thermodynamic parameters that limit electrodissolution and the consideration of grain orientation on these regimes are elucidated. At low Cr(III) concentrations, the corrosion process is governed by charge transfer control at low overpotentials and is crystal orientation dependent. However, when Cr(III) concentrations are high or when there is a high overpotential, the formation of a metal fluoride salt film on the Cr surface shifts the kinetic behavior to be governed by mass transport control at all anodic potentials with a surface morphology controlled by salt film deposition location and identity. Evan’s diagrams were developed to consolidate and elucidate these observations. These findings were supported by an examination of the post-corrosion microstructure, X-ray diffraction of solidified salts, and thermo-kinetics analysis in each corrosion regime.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗

DOE OSTI2025

Improving high temperature resilience of fiber sensor embedded smart components through laser shock peening

This study explores the use of laser shock peening (LSP) to enhance material properties and high-temperature performance of fiber-sensor-fused smart parts fabricated by additive manufacturing (AM) methods. Using embedded fiber sensors as distributed strain gauges, the study demonstrates that LSP can induce compressive strains of up to 130 µε on fiber embedded 1-mm below metal surfaces. The electron backscatter diffraction (EBSD) analysis shows that, with optimized LSP parameters, the metallic matrix undergoes substantial microstructural refinement, resulting in denser structures. Thermal cycling tests showed that the LSP process can increase fiber slippage temperatures by more than 50 °C. This work shows that the LSP process is an effective room-temperature process for enhancing both surface quality and increasing fiber slippage threshold under both thermal and mechanical stress.

Zhong, Shuda [University of Pittsburgh, PA (United↗

DOE OSTI2015

Rolling Process Modeling Report. Finite-Element Model Validation and Parametric Study on various Rolling Process parameters

Pacific Northwest National Laboratory (PNNL) has been investigating manufacturing processes for the uranium-10% molybdenum alloy plate-type fuel for high-performance research reactors in the United States. This work supports the U.S. Department of Energy National Nuclear Security Administration’s Office of Material Management and Minimization Reactor Conversion Program. This report documents modeling results of PNNL’s efforts to perform finite-element simulations to predict roll-separating forces for various rolling mill geometries for PNNL, Babcock & Wilcox Co., Y-12 National Security Complex, Los Alamos National Laboratory, and Idaho National Laboratory. The model developed and presented in a previous report has been subjected to further validation study using new sets of experimental data generated from a rolling mill at PNNL. Simulation results of both hot rolling and cold rolling of uranium-10% molybdenum coupons have been compared with experimental results. The model was used to predict roll-separating forces at different temperatures and reductions for five rolling mills within the National Nuclear Security Administration Fuel Fabrication Capability project. This report also presents initial results of a finite-element model microstructure-based approach to study the surface roughness at the interface between zirconium and uranium-10% molybdenum.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2017

Enhancements to Engineering-scale Reactor Pressure Vessel Fracture Capabilities in Grizzly

The Grizzly code is being developed to model the effect of aging in nuclear power plant systems, components, and structures. A significant part of this effort has been to develop capabilites to model the effects of embrittlement in reactor pressure vessels on their integrity. This includes both modeling of microstructure and engineering property evolution, and engineering-scale probabilistic fracture mechanics analysis. This report documents recent advances to the engineering-scale fracture mechanics capability for evaluation of RPV integrity under transient loading in Grizzly. These developments are in three areas: probabilistic fracture mechanics, general reduced order models for fracture a flaw locations, and improvments to the XFEM capability used in Grizzly for fracture mechanics analysis. The combination of these developments brings Grizzly closer to a state where it can be applied in production as a general tool for engineering-scale fracture mechanics analysis. The probabilistic fracture mechanics capabilities are included in the 1.5 testing version of Grizzly, and will be further refined in preparation for production use in the 2.0 released planned for fiscal year 2018.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2020

FY20 Status Report on Creep Rupture Testing to Support the Development of Alloy 709 Code Case

This report provides an update on the status of the creep rupture testing on the first commercial heat of Alloy 709 in support of the Alloy 709 Code Case development. A creep test laboratory has been set up at ANL that comprises of 15 indirectly loaded test frames capable of testing ASTM-size specimens of the commercial heat of Alloy 709. The systems are equipped with high temperature furnaces capable of operation up to 1000°C in an air environment. During FY18, uniaxial ASTM-sized creep specimens were fabricated from 9 Alloy 709 plates that were processed by AOD, ESR, and ESR-homogenized routes and subsequently solution annealed at 1050, 1100, and 1150°C, and creep-rupture tests were performed at 330MPa and 600°C. The test results led to the down selection of the ESR-1100°C condition to support the code case. In FY19, 15 creep-rupture tests of the ESR-1100°C material, requiring the use of Type K thermocouples, were initiated to support the 100,000-hour Code Case. 8 tests were completed in FY19. In FY20, 6 tests were completed at the time of writing this report. In addition, 1 more test were loaded in FY20, using Type S thermocouples, and was completed. This report presents the data from the completed tests in FY20 and also the microstructural characterization of the fractured specimens. The creep data enabled the preliminary analysis of the creep behavior of this material. The characterization showed that in brittle fractures, the pores were narrow and thin, and elongated in the direction perpendicular to the loading direction, while in ductile fractures, the pores were much rounder. Dense precipitates were observed in all the samples, the size of which grew with test temperature. Some of the precipitates could be identified to be M23C6 based on their cuboid shape.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗

DOE OSTI2012

Room temperature ductility of NiAl-strengthened ferritic steels: Effects of precipitate microstructure

The effects of precipitate microstructure on the room temperature ductility of a series of carefully designed Fe-Al-Ni-Cr-Mo steels were investigated. Transmission electron microscopy (TEM), ultra small angle X-ray scattering (USAXS), and atom probe tomography (APT) were conducted to quantify the nano-scaled precipitates. The accuracy of the characterization results was verified by a numerical analysis. Three point bending tests results demonstrated that ductility was a function of the precipitate volume fraction and the Al and Ni concentrations in the Fe matrix, these relationships were discussed in terms of possible mechanisms. The ductility was also found to be independent of the precipitate size and inter-particle spacing in the studied range, which was validated by a theoretical model.

36 MATERIALS SCIENCE↗

DOE OSTI2016

Electrochemical lithiation of silicon with varied crystallographic orientation

The anisotropy of lithium intercalation into the silicon anodes of Li-ion batteries is studied on microstructures having the form of a grid with 0.5-μm-thick vertical walls and on silicon wafers of varied orientation. Electrochemical lithiation is performed at room temperature in the galvanostatic mode. The charging curves of the microstructure and flat Si anodes are examined. Secondary-ion mass spectroscopy is used to determine the distribution of intercalated Li atoms across the wafer thickness. The experimental data are analyzed in terms of the two-phase model in which the lithiation process is limited by the propagation velocity of the front between the amorphous alloy with a high Li content and the crystalline Si substrate. The relationship between the rates of Li intercalation into different crystallographic planes: (110), (111), and (100), is found to be V{sub 110}: V{sub 111}: V{sub 100} = 3.1: 1.1: 1.0. It is demonstrated that microstructure anodes with (110) walls have the highest cycle life and withstand ~600 cycles when charged and discharged at a rate of 0.36 C.

36 MATERIALS SCIENCE↗

DOE OSTI2013

Efficient simulation of press hardening process through integrated structural and CFD analyses

Press hardened steel parts are being increasingly used in automotive structures for their higher strength to meet safety standards while reducing vehicle weight to improve fuel consumption. However, manufacturing of sheet metal parts by press hardening process to achieve desired properties is extremely challenging as it involves complex interaction of plastic deformation, metallurgical change, thermal distribution, and fluid flow. Numerical simulation is critical for successful design of the process and to understand the interaction among the numerous process parameters to control the press hardening process in order to consistently achieve desired part properties. Until now there has been no integrated commercial software solution that can efficiently model the complete process from forming of the blank, heat transfer between the blank and tool, microstructure evolution in the blank, heat loss from tool to the fluid that flows through water channels in the tools. In this study, a numerical solution based on Altair HyperWorks® product suite involving RADIOSS®, a non-linear finite element based structural analysis solver and AcuSolve®, an incompressible fluid flow solver based on Galerkin Least Square Finite Element Method have been utilized to develop an efficient solution for complete press hardening process design and analysis. RADIOSS is used to handle the plastic deformation, heat transfer between the blank and tool, and microstructure evolution in the blank during cooling. While AcuSolve is used to efficiently model heat loss from tool to the fluid that flows through water channels in the tools. The approach is demonstrated through some case studies.

36 MATERIALS SCIENCE↗

DOE OSTI2011

Microstructural characterization of high-manganese austenitic steels with different stacking fault energies

Microstructures of tensile-deformed high-manganese austenitic steels exhibiting twinning-induced plasticity were analyzed by electron backscatter diffraction pattern observation and X-ray diffraction measurement to examine the influence of differences in their stacking fault energies on twinning activity during deformation. The steel specimen with the low stacking fault energy of 15 mJ/m{sup 2} had a microstructure with a high population of mechanical twins than the steel specimen with the high stacking fault energy (25 mJ/m{sup 2}). The <111> and <100> fibers developed along the tensile axis, and mechanical twinning occurred preferentially in the <111> fiber. The Schmid factors for slip and twinning deformations can explain the origin of higher twinning activity in the <111> fiber. However, the high stacking fault energy suppresses the twinning activity even in the <111> fiber. A line profile analysis based on the X-ray diffraction data revealed the relationship between the characteristics of the deformed microstructures and the stacking fault energies of the steel specimens. Although the variation in dislocation density with the tensile deformation is not affected by the stacking fault energies, the effect of the stacking fault energies on the crystallite size refinement becomes significant with a decrease in the stacking fault energies. Moreover, the stacking fault probability, which was estimated from a peak-shift analysis of the 111 and 200 diffractions, was high for the specimen with low stacking fault energy. Regardless of the difference in the stacking fault energies of the steel specimens, the refined crystallite size has a certain correlation with the stacking fault probability, indicating that whether the deformation-induced crystallite-size refinement occurs depends directly on the stacking fault probability rather than on the stacking fault energies in the present steel specimens. - Highlights: {yields} We studied effects of stacking fault energies on deformed microstructures of steels. {yields} Correlations between texture and occurrence of mechanical twinning are discussed. {yields} Evolutions of dislocations and crystallite are analyzed by line profile analysis.

36 MATERIALS SCIENCE↗

DOE OSTI2012

Full quantitative phase analysis of hydrated lime using the Rietveld method

Full quantitative phase analysis (FQPA) using X-ray powder diffraction and Rietveld refinements is a well-established method for the characterization of various hydraulic binders such as Portland cement and hydraulic limes. In this paper, the Rietveld method is applied to hydrated lime, a non-hydraulic traditional binder. The potential presence of an amorphous phase in this material is generally ignored. Both synchrotron radiation and a conventional X-ray source were used for data collection. The applicability of the developed control file for the Rietveld refinements was investigated using samples spiked with glass. The results were cross-checked by other independent methods such as thermal and chemical analyses. The sample microstructure was observed by transmission electron microscopy. It was found that the consistency between the different methods was satisfactory, supporting the validity of FQPA for this material. For the samples studied in this work, the amount of amorphous material was in the range 2-15 wt.%.

36 MATERIALS SCIENCE↗

DOE OSTI2023

Utah FORGE: Well 16A(78)-32 Core Analysis Results

This dataset features petrographic, X-Ray Diffraction (XRD), and Scanning Electron Microscopy Analyses of core samples from well 16A(78)-32, which serves as the injection well for the Utah FORGE Enhanced Geothermal System (EGS) project. In addition to an overview of the analysis, the following items have been included here: images of 21 entire thin sections in plane-polarized and cross-polarized light from 16 depths, scanning electron microscope back scatter electron photomosaic maps of 21 thin sections from 16 depths, bulk XRD data from 16 depths, clay-sized XRD patterns from 16 depths, an optical petrography report, and scanning electron microscopy and energy dispersive spectroscopy analyses of eight selected samples.

15 GEOTHERMAL ENERGY↗

DOE OSTI2018

Very High Cycle Fatigue of a Cast Aluminum Alloy: Size Effect and Crack Initiation

Fatigue properties of an Al-Si-Cu cast alloy were investigated with life up to very high cycle fatigue regime. Particular attention was given to specimen size effect and fatigue crack initiation mechanism. Uniaxial fatigue tests with constant amplitudes were carried out by using ultrasonic fatigue testing machine operating at 20 kHz, compared to the results obtained by using conventional hydraulic fatigue machine at 35 Hz. In order to evaluate the size effect, two sets of specimens with different dimensions were used. The results show that the fatigue strength of the studied alloy decreases with the increase in specimen size. Scanning electron microscopy observation of fracture surfaces revealed that most fatigue cracks initiated from microstructural defects such as porosity located on specimen surface or in subsurface. Weibull statistical analysis of fatigue data accounting for size effect was performed to predict the fatigue life of the Al-Si-Cu alloy in the very high cycle regime. Good agreement was found between the fatigue life prediction and the experimental data.

36 MATERIALS SCIENCE↗

DOE OSTI2020

Microstructure study of U–35 wt.% Zr alloy after quick annealing at 650 °C

Uranium-35wt.%zirconium (U-35wt.%Zr) alloy was annealed for 1 hour and 24 hours at 650 ºC and characterized to understand the early stage microstructure evolution. Dendritic microstructure with fine (~300 nm in length) α-U precipitates clustered between dendrite branches were observed in the 1-hour annealed sample. After 24-hour annealing 650 ºC, the α-U precipitates coarsened, and the dendritic microstructure disappeared due to microstructure homogenization. Furthermore, microchemical homogenization observed with Energy-Dispersive X-ray Spectroscopy analysis suggests that α-U precipitates are approaching thermodynamic equilibrium in the 24-hour annealed sample. The findings from this study have potential impacts on the manufacturing and computer modeling of metallic nuclear fuel.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗

DOE OSTI2018

Formation and Properties of Locally Tensile Strained Ge Microstructures for Silicon Photonics

The formation and properties of locally tensile strained Ge microstructures (“microbridges”) based on Ge layers grown on silicon substrates are investigated. The elastic-strain distribution in suspended Ge microbridges is analyzed theoretically. This analysis indicates that, in order to attain the maximum tensile strain within a microbridge, the accumulation of strain in all corners of the fabricated microstructure has to be minimized. Measurements of the local strain using Raman scattering show significant enhancement of the tensile strain from 0.2–0.25% in the initial Ge film to ~2.4% in the Ge microbridges. A considerable increase in the luminescence intensity and significant modification of its spectrum in the regions of maximum tensile strain in Ge microbridges and in their vicinity as compared to weakly strained regions of the initial Ge film is demonstrated by microphotoluminescence spectroscopy.

36 MATERIALS SCIENCE↗

DOE OSTI2018

Hot Deformation Behavior and Microstructural Evolution of Antibacterial Austenitic Stainless Steel Containing 3.60% Cu

Hot deformation behavior of as-cast antibacterial austenitic stainless steel containing 3.60% copper was investigated in a temperature range of 900-1150 °C and strain rate range of 0.01-20 s{sup −1}. At strain rates higher than 1 s {sup −1}, the flow stress curves were corrected considering adiabatic heating. Kinetic analysis indicated that the hot deformation activation energy of steel was 376.02 kJ mol{sup −1}. The microstructural evolution under different temperatures was observed by optical microscopy. The nucleation sites for recrystallization and different orientations and twin ratios under different strain rates were analyzed by electron backscatter diffraction. The results showed that hot deformation was dominated by continuous dynamic recrystallization in the high-temperature and high-strain-rate region (1050-1150 °C, 1-20 s{sup −1}). On increasing the temperature and strain rate, the degree of recrystallization and twinning increased simultaneously. These phenomena promoted one another. Thus, the volume fraction of the recrystallized and twinned grains increased with the addition of Cu.

36 MATERIALS SCIENCE↗